Masonry and concrete forming scheme and apparatuses

ABSTRACT

Novel methods of in situ forming masonry and concrete structures at least include providing stock lumber to serve as frame members, removably joining at least two frame members by at least one manufactured frame member joiner, placing masonry elements and/or concrete (or cement) between said joined frame members, separating the joined frame members from the resultant structure of masonry elements and/or concrete created, and removing the joined frame members from said frame member joiners. The frame member joiner includes at least two sleeve members, each sleeve member adapted to receive and hold in place during masonry element and/or concrete (or cement) placement, a frame member.

FIELD OF THE INVENTION

The present invention generally relates to improved methods andapparatuses for the on-site forming of masonry and concrete structures.More particularly, the present invention relates to improving theformation and removing of frames used in on-site masonry and concreteprojects.

BACKGROUND OF RELATED ART

Many prior art on-site masonry and concrete projects require the use offrames to serve as molds or boundaries. The typical approach to framesis to either use a completely pre-fabricated frame that can beexpensive, bulky and not easily portable or maneuverable, or constructmakeshift frames by nailing or screwing stock lumber together. Thepre-fabricated approach typically uses expensive steel frame members.Additionally, such frames are usually only assembled in oneconfiguration, which may not give a contractor/mason the flexibilityneeded at a work site.

The latter approach solves some of the problems associated with thepre-fabricated frame approach, but introduces other limitations. In asimple example, a contractor/mason desiring to construct a driveway outof brick or concrete might form a long frame member by nailing two ormore boards (such as two-by-fours and two-by-sixes) end-to-end. Boardsare then nailed to each other forming other angles (such asperpendicular orientations) as needed until the makeshift frame enclosesthe target area.

Subsequently, the contractor/mason can pour concrete or cement asappropriate, and install masonry elements such as bricks as desired.Upon sufficient drying of the work the frame can be dismantled andremoved.

The latter approach to on-sight frame formation can lead to framemembers that are not sufficiently aligned, introducing an unacceptablevariance from the desired dimensions at times. Further, the joining offrames can be unnecessarily time-consuming. Additionally, this approachoften damages the ends of the lumber to an extent that it is notreusable in future frames.

What is therefore needed but absent in the prior art, is a flexibleframe approach for on-site masonry and concrete projects in which theframe can be quickly, inexpensively and accurately formed and removed atthe work site, and in which greater flexibility of the orientation ofthe frame members is also possible.

SUMMARY

In view of the above-identified limitations of the prior art, thepresent invention provides an improved method of in situ forming masonrystructures. The method at least includes providing stock lumber to serveas frame members, removably joining at least two frame members by atleast one manufactured frame member joiner, placing masonry elements andcement between the joined frame members, separating the joined framemembers from the resultant structure of cement and masonry elementscreated, and removing the joined frame members from the frame memberjoiners. The frame member joiner includes at least two sleeve members,each sleeve member adapted to receive and hold in place during masonryelement and cement placement, a frame member.

The present invention also provides an improved method of in situforming concrete structures. The method at least includes providingstock lumber to serve as frame members, removably joining at least twoframe members by at least one manufactured frame member joiner, pouringconcrete between joined frame members, separating the joined framemembers from the resultant concrete structure created, and removing thejoined frame members from the frame member joiners. The frame memberjoiner includes at least two sleeve members, each sleeve member adaptedto receive and hold in place during concrete pouring, a frame member.

The present invention further provides an article of manufacture adaptedto form at least a portion of a frame for the in situ forming of masonrystructures. The article of manufacture includes at least two joinedsleeve members, wherein each sleeve member is adapted to receive andhold in place during masonry element and cement dispensing, a framemember.

BRIEF DESCRIPTION OF THE DRAWINGS

Features of the present invention will become apparent to those skilledin the art from the following description with reference to thedrawings, in which:

FIG. 1 is a plan view of a frame formed using the present-inventivearticles of manufacture and the present-inventive method of frameformation;

FIG. 2 is a more detailed version of FIG. 1 showing masonry elementsplaced in the mold formed by the frame of FIG. 1;

FIG. 3 is a top view of one version of the present-inventive article ofmanufacture for joining frame members, which also shows frame membersecuring means;

FIG. 4 is a front view of the article of manufacture introduced in FIG.3;

FIG. 5 is a top version of a second version of the present-inventivearticle of manufacture for joining frame members;

FIG. 6 is a top version of a third version of the present-inventivearticle of manufacture for joining frame members;

FIG. 7 is a top version of a fourth version of the present-inventivearticle of manufacture for joining frame members;

FIG. 8 is a top view of a fifth version of the present-inventive articleof manufacture for joining frame members, which also shows a pivotalsleeve member; and

FIG. 9 is a side view of the article of manufacture introduced in FIG.8.

DETAILED DESCRIPTION

The present invention is a novel approach to forming frames on site formasonry and concrete projects such as sidewalks, driveways, roads,floors, patios, etc. As introduced in the “Summary,” supra, framemembers consisting of stock lumber (in the preferred embodiment) areinserted into special articles of manufacture here labeled as framemember joiners.

A simple frame 100 formed using the present-inventive articles ofmanufacture and method is shown in FIG. 1. In the illustration, fourinventive frame member joiners 110 are shown with four frame members120, 130, 140 and 150 inserted therein to form a frame for the boundaryof a masonry or concrete project. While the frame is in a rectangularform, other non-rectangular frames can be formed using thepresent-inventive frame joiners 110.

FIG. 2 shows a near completed masonry project, where a frame surrounds aworkspace 160 filled with cement 164 and masonry elements such asbricks, stones or blocks 168. After the molding is complete, the framecan either be removed from the project as a unit, or it can bedismantled as will be explained infra.

FIGS. 3 through 9 all illustrate various embodiments of thepresent-inventive frame member joiners. The frame member joiners arearticles of manufacture that can be made of any suitable material suchas plastic or metal. However, the preferred embodiment frame memberjoiners are molded plastic, and can be discarded after a single use ifdesired. What each embodiment for a frame member joiner has in common isat least two sleeve members dimensioned to accept and hold in place, aframe member. Therefore, when stock lumber is used, the sleeve membersare dimensioned to accept the end cross-section of particular boards(i.e., a different frame joiner may be used to join “two-by-fours” asopposed to “two-by sixes,” for example) in a reasonably, but not overlysnug fit.

The frame member joiner 110 in Figure has three sleeve members 312, 314and 316, for receiving two or more stock lumber frame member boards. Thetop view of FIG. 3 is further augmented by the front view of FIG. 4. Inthis example, the frame member joiner 110 also has securing devices 320and 330 to providing extra holding of the lumber during the completionof the construction job. The securing devices are optional, however. Thesecuring device 330 is merely a hole, through which lumber can betemporarily nailed or engaged by a screw. The securing device 320 is aflange member biased toward the center of the sleeve member, the flangemember holding the lumber in place when the lumber is inserted in thesleeve. Prior to removing lumber from a sleeve member, a tab 322 is usedto pull the flange member 320 away (e.g., using a flathead screwdriveror the like) from the lumber to disengage it.

Examples of many variations on the present-inventive frame member joinerare shown in the remaining drawing figures. Given the teachings in thisLetters Patent, many other variations are possible. The frame memberjoiner 510 in FIG. 5 acts as an extender, and accepts two frame membersto form a longer boundary. The frame member joiner 610 in FIG. 6 joinstwo frame members at right angles. Meanwhile, the frame member joiner710 in FIG. 7 not only illustrates that frame member joiner of thepresent invention can have three or more sleeve members, but that thesleeve members can also be oriented at relative angles other than 90°and 180°.

FIGS. 8 and 9 show the top and side views, respectively, of a framemember joiner 810 where at least one of the sleeve members 890 can bemoved to an arbitrary angle relative to one or more of the other sleevemembers (870 and 880). The sleeve member 890 contains two rigid flanges894 that pivot about a pin 898.

Variations and modifications of the present invention are possible,given the above description. However, all variations and modificationswhich are obvious to those skilled in the art to which the presentinvention pertains are considered to be within the scope of theprotection granted by this Letters Patent.

1. A method of in situ forming masonry structures comprising: providingstock lumber to serve as frame members; removably joining at least twoframe members by at least one manufactured frame member joiner; placingmasonry elements and cement between said joined frame members;separating the joined frame members from the resultant structure ofcement and masonry elements created; and removing the joined framemembers from said frame member joiners; wherein said frame member joinercomprises at least two sleeve members, each sleeve member adapted toreceive and hold in place during masonry element and cement placement, aframe member.
 2. A method of in situ forming concrete structurescomprising: providing stock lumber to serve as frame members; removablyjoining at least two frame members by at least one manufactured framemember joiner; pouring concrete between joined frame members; separatingthe joined frame members from the resultant concrete structure created;and removing the joined frame members from said frame member joiners;wherein said frame member joiner comprises at least two sleeve members,each sleeve member adapted to receive and hold in place during concretepouring, a frame member.
 3. An article of manufacture adapted to form atleast a portion of a frame for the in situ forming of masonrystructures, said article of manufacture comprising: at least two joinedsleeve members; wherein each sleeve member is adapted to receive andhold in place during masonry element and cement dispensing, a framemember.
 4. The method of claim 1, wherein said frame members are stocklumber.
 5. The method of claim 1, further comprising at least threesleeve members.
 6. The method of claim 1, wherein said sleeve membersare oriented so that at least two joined frame members form parallel orperpendicular angles.
 7. The method of claim 1, wherein said sleevemembers are oriented so that at least two joined frame members formnon-parallel and non-perpendicular angles.
 8. The method of claim 1,wherein said sleeve members are pivotally attached so that frame membersform an angle adjustable by a user.
 9. The method of claim 1, whereinsaid sleeve members comprise securing devices adapted to secure engagedframe members during masonry element and cement placement.
 10. Themethod of claim 1, wherein said frame member joiners are adapted to bedisposable after a single use.
 11. The method of claim 2, wherein saidframe members are stock lumber.
 12. The method of claim 2, wherein saidsleeve members are pivotally attached so that frame members form anangle adjustable by a user.
 13. The method of claim 2, wherein saidsleeve members comprise securing devices adapted to secure engaged framemembers during masonry element and cement placement.
 14. The method ofclaim 2, wherein said frame member joiners are adapted to be disposableafter a single use.
 15. The article of manufacture of claim 3, whereinsaid sleeve members are pivotally attached so that frame members form anangle adjustable by a user.
 16. The article of manufacture of claim 3,wherein said sleeve members comprise securing devices adapted to secureengaged frame members during masonry element and cement placement. 17.The article of manufacture of claim 3, further adapted to be disposableafter a single use.
 18. The article of manufacture of claim 16, whereinsaid securing devices comprise flange members biased to the centerlineof the sleeve member to which said securing device is attached, saidflange member being adapted to hold said frame members in place whilesaid frame members are inserted into said sleeve members, and saidflange members are adapted to be pried away from said frame members forremoval of said frame members.
 19. The article of manufacture of claim16, wherein said securing devices comprise a region of said sleevemembers having a hole adapted to receive a nail or screw through saidhole into said frame members to hold said frame members in place whilesaid frame members are inserted into said sleeve members.
 20. Thearticle of manufacture of claim 3, further comprising at least threesleeve members.